Archive · 9 Dec 2025
Lessons from EV Global Launch Simulation
Launching an electric vehicle (EV) globally is a big task.
Vijayachandar Sanikal, a leader in virtual simulations, shares how using digital tools can make this process easier.
By using simulations and synthetic data, his team was able to test and improve EV systems before building physical prototypes.
This approach saved time and money, and made sure the vehicles were ready for different markets.
They created special libraries and tools to test how the cars would perform in different conditions.
Sanikal also published research on using these methods to improve EV reliability and safety.
He believes that the future of EV engineering lies in testing and decision-making earlier in the design process, using digital twins and continuous calibration loops.
Vijayachandar Sanikal, a virtual Simulation Integration leader, has played a crucial role in the global rollout of next-generation battery electric vehicles (BEVs).
His work focused on virtual integration, ensuring that each component aligns with vehicle targets like acceleration, range, and energy efficiency.
The team used digital twins and Model-/Software-/Hardware-in-the-Loop systems to pre-tune vehicle systems, reducing development time and minimizing risks.
By utilizing virtual testing and automated regression suites, the team achieved more than a 10% reduction in the pre-PD prototype budget and saved substantial costs.
Sanikal led the development of enterprise-wide methods that improved reusability, consistency, and global alignment, including the Global Duty-Cycle and Climate Library and Thermal/Energy Digital Twins.
- Who
- Vijayachandar Sanikal, a virtual Simulation Integration leader
- What
- Lessons from the global launch of electric vehicles using virtual simulations
- When
- Not specified
- Where
- Global EV development
- Why
- To balance technical innovation with real-world performance and ensure smoother, more predictable global launches
- Lead
- Vijayachandar Sanikal
- Role
- Virtual Simulation Integration Lead
- Key Tools
- Digital twins, Model-/Software-/Hardware-in-the-Loop systems
- Cost Savings
- More than 10% reduction in pre-PD prototype budget
- Key Initiatives
- Global Duty-Cycle and Climate Library, Thermal/Energy Digital Twins, SiL/HiL Regression Farm
- Publications
- Machine Learning Models for Predictive Maintenance of EV Thermal Systems, Utilization of Bench Testing in Vehicle Thermal System Development for Extreme Cold Ambient Conditions